'62 Chop, 4th Rebuild in 42 years..... - Page 6 - The Jockey Journal Board

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Old 12-08-2014, 10:28 PM   #101
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Dad always had bikes, so I grew up learning to ride with my Dad and his brothers.

I love this bike, the '62FL, my first Harley Davidson and my third bike, a bike brand my Dear Old Dad rode for many, many miles and years.

After high school I was at UC Davis, in an Ag Machinery Engineering program, and paying my bills by working at the UCD fire station. There were always fireman around the station with bikes, so I got to ride a lot. I was staff, drove and maintained a '35 Dodge ladder truck (a short ladder truck, only went up three stories. No siren so I welded up headers with zoomies so they would hear us coming....)

But I also loved a 305 cc Honda Super Hawk, my first bike that I actually owned. After graduation I landed a great job in NorCal, when I bought the '63 Honda Super Hawk.

I had set it up off road style with high pipes, a bash plate, and really great knobby tires that loved to dance from side to side when out on the highway, age 21....

Then I sold the Honda, and bought a real good deal on a one year old '64 BSA 650 cc twin carb Lightning.

So I set it up off road style with high pipes, a bash plate, knobby tires that loved to dance from side to side when out on the highway, age 23....

Was invited to work running surveying and mapping at a Maui sugar cane plantation, brought the Beezah along, it was a great boonie basher, as the plantation connection lead to the ranches, where I got to go full moon midnight boonie bashin' with the ranch guys, way too cool!

But the guys I was riding with on the street were all riding Harley and Indian flatties, knuckles and pans (think 1967, a shovel was a rare sight back then...) !

I had a second set of rims with street tires, so it was an easy 10 minute adjustment back to street riding for an inspired 25 year old!!

So I got inspired to buy a '62 from a friend while on a long trip all over the big island with a bunch of friends in '67. I was riding the BSA, and a buddy was riding the '62. It was a bobbed ex Honolulu Police Dept bike. So I'm the second owner not counting the HPD. One Hawaiian guy then me.

I was working on the HD in the living room of a sugar plantation house, located in the mill town where I worked. And when I met my wife, she was amused but kept on smiling, and sorta tolerated my "chopper shop" until I got the '62 completely chopped the first time and out of the "living room". She wanted her living room back.

'Nuff fo' now....
Willy

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Old 12-11-2014, 12:12 PM   #102
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Finally got 'er pulled apart, and the frame and tank are on the way to the media blast guy....

(This is a busy shop, there are presently my bike and my 55 Chevy, plus 2 trucks, a roadster, a 9 second drag strip car, and a couple other basic transport cars just being kept alive....)

All the parts lined up, motor and tranny on another bench....


My seat, I made a fiberglass seat pan for this, copied from an original Indian Scout steel pan that I had made a mold off of...


Motor, tranny, wheels, forks are all done. Now to do the rest of it and put it back together!
Aloha,
Willy

more PIX are here....

Last edited by 2Loose; 12-11-2014 at 12:24 PM.
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Old 12-11-2014, 12:23 PM   #103
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I wish I didn't' work so much right now, but I gotta make hay while the sun shines. I wish I was there helping. Love this bike.
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Old 12-11-2014, 12:26 PM   #104
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Jaws, I stole the gas tank off the "P-Driver" yesterday when nobody was looking, gonna try to get a paint match today....

And the machine shop has the adapter for the front disk brake.
Wish I had access to a good lathe, I'd like to try my hand at turning that down myself!
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Old 12-11-2014, 12:41 PM   #105
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

You know you are welcome to anything at my house, parts, bike, cars, whatever. I wish I had a lathe too.
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Old 01-16-2015, 06:51 PM   #106
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Finally got some lathe time,
set up the large 3/8" disk to be cut for the rotor carrier first....


Then cut the 3/16" shoulder to fit the disk rotor....


Got a really good fit with the disk, and only cut the shoulder to 1/8", leaving a thicker piece backing
the rotor....


Flipped it around and started on the 3/4" piece to fit in the '62 Star hub....


Cleaned up and beveled out the weld while we were at it....


Then ran a series of increasingly larger drill bits in the center until it was large enough to get a
cutting tool in there, and took it out to get a snug fit on the Star hub....


Time for a check fit on the '62's front wheel....


Right side looks good too....


More later,
Willy
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Old 01-16-2015, 06:52 PM   #107
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

OK, now it's time to drill and tap for the disk on the disk carrier....

The bolts for the original Suzuki rotor are allen head, 8 mm, 1.25 thread.
There is also a 10 mm shoulder on the bolts that fits the 10 mm holes in the rotor, and locks
into the disk carrier an additional 2 mm before the 8 mm thread starts in the carrier.
My transfer punches are all US, but the 13/32" punch fits nicely in the 10 mm hole,
and allows me to accurately center punch the six holes.


Punched, drilled and tapped 2 holes opposite each other.
The tap is an 8 mm, 1.25 thread, so trying to find a starter hole size for the tap
was a bit of a problem. A 6.8 mm drill was spec'd, or 0.268".
A 17/64" bit was used, it is 0.266", just slightly tight for this tap,
But by using a good quality cutting oil, and working the tap through
the metal carefully, it went very well.


Drilled the center punches first with a small bit, I used a 3/32" on this one.
Then followed up with the 17/64" drill, then ran the tap through.


The disk carrier has not been countersunk yet for the shoulder on these bolts,
so flipped the rotor over and put the bolts in for now from the back side just to check it all out.


The bolts are a bit long, and looks like there may be some interference with the spokes.
But I need to get a 10 mm drill to countersink the carrier holes a bit for the shoulders
on these bolts, then I can figure the total bolt length I can get away with on this setup.


Just some pix of the 8 mm tap and the bolts themselves.


Here you can see why I need to countersink the 10 mm hole into the carrier
to accomodate that shoulder on the bolt....


Checking the backside bolt length against the spokes, need to be shortened slightly,
but the carrier needs to be countersunk first, with the rotor flipped back over
which will expose more thread. Want to run some ss acorn nuts on these threads.


Put the caliper on to check it out, looks good and clears the spokes.


When it is all setup and pressurized will be the final check.
Since the piston is on the outside, the floating caliper will move
away from the spokes as the pads wear down.


Here the bolt heads are exposed because the carrier holes have not been
countersunk yet, they will be flush with the rotor once the countersunk holes
have been drilled and the rotor flipped over to accommodate the flats on the bolt heads.


More Later,
Aloha,
Willy

More Pix Here....
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Old 01-17-2015, 12:03 AM   #108
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

You have been busy. Looks great!
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Old 01-22-2015, 03:22 PM   #109
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Countersunk the bolt holes on the rotor side with a 25/64" drill,
seemed to work well for the 10 mm shoulder on these rotor bolts....

Then two washers and a hex nut provided the correct height on the bolt threads
to shorten them for the acorn nuts....
Perfect fit....
I think this would look good on the spoke side of the brake rotor,
but unfortunately they were just a hair too close to the spokes, so will have to
just run the hex nuts....

The other alternative is to machine a spacer where this center hub fits
into the wheel's star hub to move it out just enough to have the
acorn nuts clear the spokes. I tried positioning the brake carrier
in many positions, but no matter where I put it, at least one or
more of the acorn nuts would hit a spoke and tilt the carrier slightly
preventing it from seating correctly in the star hub !
A thin spacer inside the star hub would correct that.
The rotor side looks great with the rotor flipped to it's correct side
and the bolts counter sunk into the carrier the correct depth....
Double checking everything for a good fit....
I want to run either flat washers or lock washers under these hex nuts to
bring them out to be flush with the end of the threads....

But they clear the spokes just fine....
Now to drill and tap the carrier for the 5/8" - 20 threads on the wheel bolts.
As that is a "special" HD thread, I have ordered taps that will cut that thread.

More later on the front disk brake...
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Old 01-22-2015, 03:42 PM   #110
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Back to the rest of the bike....

Tryin' to match the original red I used back in the late 60's on this bike.

Compared it to the red on my '58 Chevy truck, which is a GM Torch Red,
It's pretty close....
Think I'm gonna go ahead with the truck color

In the meantime, sent the frame, tank and rear fender off to the sandblaster....
I actually like that light gray color a lot !!

Yeah, that's my '55 Chevy Viking series 4x4 parts chaser....
I love this tank, want to do something special with the concave on the sides....
More Later....
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Old 01-22-2015, 04:28 PM   #111
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Nice work, it's coming along great. Could you shorten the acorn nuts a bit to get them to clear the spokes? Maybe shave the hex face a little, and depending how they're made, lose a touch off the dome too?
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Old 01-22-2015, 04:56 PM   #112
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Great work on the star hub Conversion.... I'll have to keep this in mind.
When it comes to Metric thread Drill size always og up 0.1mm... for example... M8 Call for 6.8mm.... go 6.9mm if you can. If you think about it... the points of the thread don't hold shit really. Will save you time tapping and remaking your work cause you snapped your tap going too tight.
Here is a real cool product instead of standard lock washers and Jam nuts.... I use this all the time now. Never failed me yet.

there are a bunch of vids,.... this is the first one I found:
https://www.youtube.com/watch?v=cDlmbMV9ICU

keep the updates coming


Lester
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Old 01-23-2015, 12:03 PM   #113
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Lester,
Thought you might like to see this photo of my '63 BSA Lightning.
Owned it from '64 to about 2000, when a local BSA collector finally
talked me out of it, he still has it in his collection, as well as a
Gold Star 500 I also had.
Aloha,
Willy
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Old 01-23-2015, 12:21 PM   #114
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by Lester View Post
......Metric thread Drill size always og up 0.1mm... for example... M8 Call for 6.8mm.... go 6.9mm if you can.....
Good Comments, as I used a drill bit that was 0.002" under to hit the 6.8mm, I was tight from the get-go, and as I only had a plug tap, it was tight right from the beginning also! Going closer to the 6.9 spec would definitely have made it easier. But with a really good thread cutting lube, and hand turning then backing off every half turn, I got it through with no problems, and the bolts fit very nicely into those holes...

I looked at trimming the underside of those acorn nuts, and decided to look at it later, it can wait as I just want to get this project back on the road and ride it!!

I'm thinking that I'll just machine a spacer to lay in the star hub to get just enough additional clearance for the acorn nuts to clear the spokes. That I can do later on. Am fashioning the carrier for the caliper, will post pix as it comes along. Also starting the paint for the sandblasted parts.

As the wheel bolts are 3/8"-20, I don't have taps for that, asked around, none of my buddies do either, so I ordered a plug tap and a bottom tap, couldn't find a tapered tap in that size, from the mainland, should be here Monday or Tuesday, then I can cut the wheel bolt holes and bolt it up. Need to do that before I can really design the caliper carrier.

And two of my 4 wheel rigs have developed problems I have to deal with now, that always slows things down !!! A leaky th400 in my 58 pro street chevy truck, and a loud clicking noise from the stick shift in my 55 chevy gasser, it never ends !!!
Aloha,
Willy

Last edited by 2Loose; 01-23-2015 at 12:28 PM.
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Old 01-23-2015, 11:24 PM   #115
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

It would if you were not a gearhead.
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Old 01-26-2015, 12:08 AM   #116
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The taps came in, so I transfer punched, drilled and tapped one hole, and

it was a perfect fit on the star hub....

In my tool drawer I have two standard 3/8" taps, a 3/8"-16 NC that requires a 5/16" drill (0.3125") and a 3/8"-24 NF that requires a Q drill (0.332") and I could not find a reference for the drill size for this 3/8"-20 tap, so I tried a 21/64" drill (0.328") and the tap was tight on that first hole, but I got it done....
Since that first hole was really too tight for the tap, I moved up to a Q bit (0.328), I transfer punched the other four holes, and drilled the 1/16" centering holes.
Drilled the four holes with the "Q" drill bit and tapped them.
The taps felt right this time, not too tight or too loose.
These are blind holes, drilled roughly 1/8" deeper than the HD wheel bolt threads.
Ran the plug tap in first, then the bottom tap to run clean threads all the way down.
The bolts all go in perfectly, and go all the way in, no problem...
The bolts and holes matched up perfectly to the star hub on the 21" wheel I'm going to use!
Just a closer look, I should never have a problem with this....
Now to design and fabricate the bracket to mount the caliper on.

Willy

Last edited by 2Loose; 01-26-2015 at 12:28 AM.
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Old 01-26-2015, 01:01 AM   #117
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Hold up on making any real changes to the legs on that AEE front.

The "new" frontend might have what you need on it. That is if you so chose to use it. Still awaiting it's arrival.
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Old 01-26-2015, 04:00 PM   #118
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Now to design and fabricate the bracket to mount the caliper on.
This is roughly the position for the caliper, up slightly, it's sitting on the disk now.


A rough sketch of what I am thinking, a bracket that floats on the axle to provide
vertical position, then a link to the old drum brake tab on the fork slider.
All cut from 1/4" steel.



I can't decide if that link back to the fork slider should be solid mount or make it floating.



Willy
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Old 01-26-2015, 04:40 PM   #119
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The caliper floats on the bracket, doesn't it? I'd make the link solid - alignment-permitting, it could even be combined with the T-shaped caliper mounting bracket mounting bracket
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Old 01-26-2015, 10:14 PM   #120
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by Rem View Post
....... it could even be combined with the T-shaped caliper mounting bracket mounting bracket
Yeah, I think so, make that whole bracket one piece, maybe even put a steel dowel of some sort on the fork slider bracket so that part of the bracket can also slide into place.

Gotta think on that a bit more, start cutting cardboard templates and see how the fit, maybe even a sheet metal template out of some 20 galv I have layin' around.
Willy
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